System for finishing printed labels using multiple X-Y cutters

Abstract

A label finishing station receives a web carrying printed images for labels arranged so there are a plurality of images formed in rows or ranks across the width of the web. The images are also arranged in longitudinal columns along the length of the web. A cutting station carries a plurality of cutter heads to cut out the plurality of labels forming each row or rank simultaneously. The web, with the label peripheries cut out, may be slit longitudinally and formed into finished rolls of labels.

What is claimed is: 
     
       1. A finishing station for a label processing apparatus comprising a source of a web having a carrier substrate and a label layer on the substrate, the web having x and y directions, a plurality of individual printed images on the label layer positioned generally in a direction along one of the x and y directions of the web to form a rank of individual printed images, a cutter head station having a plurality of cutter heads associated with a plurality of individual printed images in a rank, the cutter heads being mounted for simultaneous movement as a unit in one of the X and Y directions, a mounting and drive mechanism for both the cutter head station and the web to provide relative movement between the cutter head station and the web in the x and y directions such that the plurality of cutter heads are operable to simultaneously cut the printed images in a rank to simultaneously form separate labels. 
     
     
       2. The finishing station of  claim 1  wherein the web is elongated along the y direction, a carriage overlying the web, the cutter heads being mounted on the carriage, and the mounting and drive mechanism comprising a support mounting the carriage for movement in a lateral direction of the web comprising the x direction. 
     
     
       3. The finishing station of  claim 1  wherein the web is elongated in the y-direction, and a plurality of ranks of individual printed images on the web positioned to form columns of printed images extending in the y-direction along the web, the cutter heads being mounted to cut portions of the label perimeters in the y direction. 
     
     
       4. The finishing station of  claim 3  further comprising a layer of film laminated over the printed images on the web, the cutter heads being moveable to a position to cut through the layer of film and the label layer at selected intervals to define the labels. 
     
     
       5. The finishing station of  claim 1  wherein the mounting and drive mechanism for both the cutter head station and the web includes a first mounting and drive mechanism comprising an anvil supporting the web at a position below the cutter head station, and drive rollers for moving the web relative to the anvil selectively in opposite directions along the y-direction, and the mounting and drive mechanism further including a second mounting and drive mechanism comprising a carriage for supporting the cutter head station and a drive for moving the cutter head station with the carriage along a support in opposite directions along the x-direction at selected intervals. 
     
     
       6. The finishing station of  claim 5 , further comprising a support bar mounted on the carriage, the plurality of cutter heads being mounted on the support bar and adjustable along the length of the support bar in the x-direction. 
     
     
       7. The finishing station of  claim 6  wherein the second mounting and drive mechanism for the cutter head station includes a cross track extending in the x-direction and fixed relative to the web, and the carriage including rollers movable along the cross track for supporting the plurality of cutter heads relative to the track. 
     
     
       8. The finishing station of  claim 7  wherein the second mounting and drive mechanism comprises an endless belt movably mounted relative to the cross track and having a portion attached to the carriage, and a controllable drive motor for driving the endless belt in opposite directions to move the carriage in the opposite directions along the x-direction. 
     
     
       9. The finishing station of  claim 2 , wherein the carriage includes a mounting shaft, the plurality of cutter heads each being mounted independently of the other cutter heads on the mounting shaft, and movable along the mounting shaft, and a lock to lock each of the individual cutter heads in a desired position along the mounting shaft. 
     
     
       10. The finishing station of  claim 1  including a frame supporting the cutter head station and the mounting and drive mechanisms for both the cutter head station and the web, the source of the web being spaced from the cutter head station, and the web elongated in the y-direction comprising a y-axis and being movable in a direction from the source toward the cutter head station and from the cutter head station to a storage, a drive roller for driving the web from the source past the cutter head station, a reversible motor driving the drive roller and controllable to drive the web back and forth along the y-direction, and a dancer roller engaging the web between the source and the cutter head station to take up slack in the web. 
     
     
       11. The finishing station of  claim 10 , further comprising a source of a laminating film sheet mounted on the frame, on a side of the web facing the label layer of the web, a laminating station on the frame for laminating the film sheet over the label layer of the web at a position such that the web moving in direction of the y-axis moves past the laminating station before the web moves to the dancer roller. 
     
     
       12. The finishing station of  claim 1  wherein the plurality of cutter heads are mounted on a common support movable laterally of the web in the x-direction, the cutter heads each comprising a cutter head housing assembly having a releasable securing device for securing the cutter head housing assembly in position along the common support on the carriage. 
     
     
       13. The finishing station of  claim 12  wherein the cutter head housing assemblies each include a first cutter head housing section mounted on the common support, and a second cutter head housing section pivotally mounted to the first cutter head housing section, the second cutter head housing section carrying a knife for engaging and cutting portions of the web, a spring between each of the first and second cutter head housing sections urging the associated knife in a direction toward the web, and an actuator mechanism for engaging one end of the spring for controlling the position of the respective second cutter head housing section about the pivot to the respective first cutter head housing section to in turn control the depth of cut into the web of the knife carried by the second cutter head housing sections. 
     
     
       14. The finishing station of  claim 13 , and a stepper motor to control the position of the actuator mechanism. 
     
     
       15. The finishing station of  claim 10 , and a slitting station on the frame having a plurality of slitting knives to slit the substrate of the web in the y-axis direction of the web to separate columns of labels formed at the cutter head station into elongated strips. 
     
     
       16. The finishing station of  claim 15  wherein the slitting knives are each mounted on a support housing pivotally mounted with respect to the frame, a latch for the support housing to hold the slitting knife mounted thereon in a slitting position to pass through the substrate of a web moving relative to the frame, and the latch being operable to release the respective knife housing for pivotable movement to a position to clear the web. 
     
     
       17. The finishing station of  claim 3  further comprising a web drive roller engaging a side of the web opposite from the label layer, a motor to drive the web drive roller, and a spring loaded pinch roller on an opposite side of the web from the web drive roller to urge the web against the web drive roller. 
     
     
       18. The finishing station of  claim 17  wherein said web drive roller is on a side of the cutter head station to receive and drive the web after the cutter heads have cut perimeters through the label layer around the plurality of separate printed images on the label layer. 
     
     
       19. A label processing apparatus for processing an elongated web having a substrate and a label layer on the substrate, a plurality of individual printed images on the label layer positioned laterally across the web to form a rank of individual printed images, a plurality of ranks of individual printed images positioned longitudinally along a longitudinal axis of the web, each printed image in a rank positioned in relation to a printed image of others of the plurality of ranks to form columns of printed images longitudinally along the web, the apparatus comprising a cutter head station having a plurality of cutter heads, the cutter heads being simultaneously movable as a unit in lateral directions relative to the longitudinal axis of the web, a drive to drive the web longitudinally while the plurality of cutter heads are moved laterally to simultaneously cut the printed images in a rank to simultaneously form a plurality of separated labels. 
     
     
       20. The label processing apparatus of  claim 19  including a frame mounting the cutter head station and the drive to drive the web longitudinally, the drive to drive the web comprising a first web drive, a lamination film supply on the frame overlying the label layer, a lamination station to laminate the film onto the label layer over the individual printed images on the label layer, the lamination station including a drive roller for driving the web, between a source of the web and the cutter station, a slack take up roller engaging the web to take up slack in the web between the lamination station and the cutter heads in the cutter head station, the first web drive being on a side of the cutter head station opposite from the lamination station, at least one storage mandrel on the frame to receive the web that has been driven through the cutter head station, the storage mandrel being separately driven, and a second spring loaded slack take up roller between the first web drive and the storage mandrel to take up slack in the first web drive and the storage mandrel. 
     
     
       21. The label processing apparatus of  claim 20  including a further web drive roller between the second slack take up roller and the storage mandrel. 
     
     
       22. The label processing apparatus of  claim 21 , and a controller to control the speed and direction of movement of the drive to drive the web longitudinally, the speed of the second drive roller, and the speed of the storage mandrel. 
     
     
       23. The label processing apparatus of  claim 22  and a sensor associated with each of the slack take up rollers, each providing a signal indicating the position of the respective slack take up roller relative to a reference position, and the signals being provided to the controller for maintaining a desired range of slack at each of the slack take up rollers. 
     
     
       24. The label processing apparatus of  claim 19 , wherein the cutter head station has a cutter head support bar, each of the cutter heads being mounted for movement along the cutter head support bar and having a first locator element thereon, a second locator element mounted at a selected lateral position of the web, the cutter heads being movable as a unit to selected cutter head positions, and individually movable along the support bar, the first and second locator elements interfitting to locate the cutter heads along the support bar with the support bar at a known location laterally of the web, and a releasable lock to lock each cutter head in position on the support bar with the first and second locator elements interfitting. 
     
     
       25. The label processing apparatus of  claim 24  wherein the first locator element comprises a machined recess, and the second locator element comprises a movable lever having a tab that closely fits the machined recess to hold the cutter head in a selected location on the support bar. 
     
     
       26. The label processing apparatus of  claim 24 , wherein the releasable lock comprises a screw on the cutter heads threadable to engage the support bar.